Adjustable fit cap with movable ear flap

ABSTRACT

An adjustable cap or headwear intended for cold weather use that includes an ear flap that is movable between a retracted and an extended position to provide additional protection for the ears of the wearer. The adjustable cap or headwear includes a pair of expansion zones formed in the crown portion of the cap that adjust the size of the head opening of the cap such that the cap can be used by wearers having different head sizes. When the ear flap is in the retracted position, the ear flap is positioned along the outer surface of the crown portion to conceal the pair of expansion zones.

BACKGROUND OF THE INVENTION

The present invention generally relates to a cap or other type ofheadwear having movable ear flaps to protect the ears of the wearer.More specifically, the present invention relates to a cap or other typeof headwear that has movable ear flaps and is adjustable to compensatefor different head sizes of the wearer.

Cold weather caps that include movable ear flaps to protect the ears ofthe wearer have been known for many years. As an example, U.S. Pat. No.1,540,405 shows a cap including a crown portion formed form a series ofgores or panels sewn together including an ear flap that is movable froma retracted position to an extended position. However, the typical capwith ear flaps shown in the '405 patent is formed from wool gores and isfitted to the specific size of the wearer's head.

Although caps having ear flaps have been available for many years, adesire exists for the mass distribution of these hats in situations inwhich the size of the wearer's head is not known. Although manydifferent hats exist that include adjustable headband sizes tocompensate for different size heads of the wearer, many of theseadjustable hats include either straps or other types of adjustmentmechanisms that can be seen from the exterior of the hat. These types ofadjustment mechanisms detract from the overall appearance of the cap andare not deemed acceptable in many applications.

SUMMARY OF THE INVENTION

The present disclosure relates to an adjustable cap or other type ofheadwear, such as a brimless hat, visor or headband, that includes amovable ear flap and one or more expansion zones that allow the cap orheadwear to adjust to the size of the wearer's head.

The adjustable cap or headwear generally includes a crown portion thatis sized to fit over at least a portion of the wearer's head. The crownportion includes a front, back and opposite sides that combine to createa lower peripheral edge that defines a head opening to receive thewearer's head. The crown portion can extend over the entire crown of thewearer's head in one embodiment of the invention. In another, alternateembodiment, the crown portion extends only over a portion of thewearer's head, such as in an embodiment in which the cap or headwear isa visor or headband.

The cap or headwear includes a movable ear flap that is positioned alongthe crown portion and is movable between an extended position and aretracted position. When the movable ear flap is in the retractedposition, the ear flap is positioned along an exterior surface of thecrown portion. When the movable ear flap is in the extended position,the ear flap extends over the ears of a wearer of the cap.

The crown portion of the adjustable cap or headwear includes at leastone expansion zone that is formed as part of the crown portion. Theexpansion zone preferably includes a stretchable material that stretchesto adjust the size of the head openings when the wearer places theadjustable cap on their head. In one embodiment, the adjustable capincludes two separate expansion zones each positioned on opposite sidesof the crown portion. The pair of expansion zones, each of which includethe stretchable material, allows the size of the head opening to beadjusted depending upon the size of the wearer's head.

When the movable ear flap is in its retracted position, the movable earflap covers the entire expansion zone and the stretchable material thatforms the expansion zone. In this manner, the stretchable material isconcealed when the ear flap is in its retracted position.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated of carryingout the invention. In the drawings:

FIG. 1 is a perspective view of an adjustable cap including a movableear flap;

FIG. 2 is a side view of the adjustable cap of FIG. 1 shown positionedon the head of a wearer with the ear flap in the retracted position;

FIG. 3 is a side view similar to FIG. 2, showing the movement of the earflap to the extended position;

FIG. 4 is a top view of the adjustable cap with the opposite sides ofthe ear flap in an untethered state;

FIG. 5 is a section view taken along line 5-5 of FIG. 2;

FIG. 6 is a section view similar to FIG. 5 illustrating the expansion ofthe adjustable cap;

FIG. 7 is a side view illustrating the inclusion of textual or graphicalinformation on the ear flap;

FIG. 8 is a perspective view of a brimless cap including the pair ofexpansion zones;

FIG. 9 is a perspective view of a headband including the pair ofexpansion zones; and

FIG. 10 is a perspective view of a visor including the pair of expansionzones.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 illustrate an adjustable cap 10 that can be used by awearer 12. Throughout the remaining portions of this description, theterm “adjustable cap” will be used in describing the embodiment shown inFIGS. 1-7. However, various other types of headwear, such as headbands,visors and brimless caps are contemplated as being within the scope ofthe invention and covered by the term “cap”.

The adjustable cap 10 includes a crown portion 14 that extends over atleast a portion of the wearer's head to provide protection for thewearer's head. In the embodiment shown in FIGS. 1 and 2, the crownportion 14 extends over the entire crown of the wearer's head. However,it is contemplated that the crown portion 14 could be truncated andextend only over a portion of the wearer's head, such as in the case ofa headband or visor. The crown portion 14 is shown in FIGS. 1 and 2 asbeing formed from a plurality of individual gores or panels 16 joined toeach other along a series of individual sewn seams 18 to define thedome-like appearance of the crown portion 14. In the embodiment shown,the cap includes six panels or gores 16, each of which are formed fromwool, although other materials are contemplated as being within thescope of the present invention.

The crown portion 14 generally includes a front 20, a back 22 andopposite sides 24. The crown portion 14 terminates at a lower peripheraledge 26 that defines a head opening 28 (FIG. 5) that receives the headof the wearer. As shown in FIGS. 1 and 2, in a first embodiment of theinvention, the adjustable cap 10 includes a bill 30 attached to thelower peripheral edge 26 at the front 20.

Referring back to FIGS. 1 and 2, the adjustable cap 10 includes amovable ear flap 32 that, in the embodiment of the inventionillustrated, extends around the entire peripheral edge of the crownportion and is joined at the front 20 of the cap by a tie 34. The earflap 32 is generally defined by a top edge 36 and a bottom edge 38 thatdefine the width of the ear flap 32. As illustrated in FIGS. 1 and 2,the right side 40 and the left side 42 of the ear flap 32 each includean end 44, 46 having an eyelet 48 that receives the tie 34 to secure theright and left sides 40, 42 of the ear flap 32.

As can be understood in FIGS. 2 and 3, the ear flap 32 is movablebetween a retracted position (FIG. 2) and an extended position (FIG. 3)to provide protection for the wearer's ears 47 as desired. The movementof the ear flap 32 between the retracted and extended position iscarried out utilizing a portion of material, referred to as a slide flap(not shown), that connects the crown portion 14 to the ear flap 32.Details of the slide flap connecting the ear flap 32 to the crownportion 14 are shown in detail in U.S. Pat. No. 1,540,405, thedisclosure of which is incorporated herein by reference.

As illustrated in FIG. 4, the right and left sides 40, 42 of the earflap 32 are each secured to the outer surface of the crown portion 14 ata point 49 past the midsection between the front 20 and the back 22 ofthe cap 10. Thus, when the tie 34 is unfastened, each of the left andright sides 40, 42 can be pulled away from the exterior surface of thecrown portion 14. When the left and right side 40, 42 are pulled awayfrom the crown portion, information can be screen printed or embroideredonto each of the right and left sides 40, 42 using conventional screenprinting machines and embroidery machines. In past caps including amovable ear flap, each of the right and left sides 40, 42 are secured tothe outer surface of the crown portion 14 much closer to the front 20,such that embroidery and screen printing on the ear flap 32 had to occurprior to attachment of the ear flap 32 to the crown portion 14.

Referring back to FIGS. 1 and 2, the adjustable cap 10 includes a pairof expansion zones 50, 52 formed in the crown portion. Each of theexpansion zones 50, 52 is included in one of the gores 16 and functionsto allow for adjustment of the size of the head opening defined by thelower peripheral edge 26. Thus, the pair of expansion zones 50, 52 allowthe size of the head opening to change when the adjustable cap 10 isplaced on the head of the wearer. The adjustable size of the headopening 28 can be seen in FIGS. 5 and 6, as illustrated by the arrows 54in FIG. 6.

Although the embodiment of the invention shown in the Figs. includes aright expansion zone 50 and a left expansion zone 52 each formed ingores 16 formed on opposite sides 24 of the crown portion 14, it iscontemplated that only a single expansion zone 50 or 52 could beutilized while operating within the scope of the present invention. Ifonly a single expansion zone is formed in the cap 10, it is contemplatedthat the single expansion zone could be formed in either side 24 of thecap or along the back 20. However, the use of a pair of expansion zones50, 52 allows for greater differences in the size of the head opening,since expansion occurs on both sides of the adjustable cap 10.

As illustrated in FIG. 2, the expansion zone 50 extends upward into thecrown portion 14 from the lower peripheral edge 26 to a top end 56.Preferably, the expansion zone 50, as well as the opposite expansionzone 52, includes a stretchable material 58 that is sewn into the sidepanel or gore 16. As an example, the stretchable material 58 may be anelastic, fabric covered section that expands as opposing forces areplaced on the front and back 20, 22 of the cap when the cap is placed ona wearer's head. Thus, the stretchable material 58 allows thecircumference of the head opening to increase or decrease depending uponthe size of the wearer's head.

As illustrated in FIGS. 2 and 3, each of the expansion zones 50, 52 iscovered by the ear flap 32 when the ear flap 32 is in the retractedposition of FIG. 2. Specifically, the top edge 36 of the ear flap 32extends above the top end 56 of the stretchable material 58 to concealthe entire stretchable material 58 when the ear flap 32 is in theretracted position.

As illustrated in FIG. 3, when the ear flap 32 is moved to its extendedposition, the top end 56 and a portion of the stretchable material 58extends slightly above the top edge 36 of the ear flap 32. Thus, onlywhen the ear flap 32 is in its extended position can the stretchablematerial 58 of the expansion zone 50 be viewed.

Referring now to FIGS. 5 and 6, the interior surface of the adjustablecap 10 includes a headband 60 that contacts the head of the wearer whenthe adjustable cap is placed on the head of the wearer. The headband 60is interrupted by the stretchable material 58 of both the expansionzones 50, 52 such that the stretchable material 58 contacts the wearer'shead. Since the headband 60 is typically formed form a material thatdoes not stretch or expand, the headband 60 is interrupted at each ofthe expansion zones 50, 52 to allow for the increase in the head opening28 depending upon the size of the wearer's head.

FIG. 7 illustrates the adjustable cap 10 having advertising orpromotional information 62 either screen printed or embroidered onto theright side 40 of the ear flap 32. As described previously, since theright and left sides 40, 42 of the ear flap 32 are secured to the crownportion near the back of the adjustable cap, the promotional oradvertising information 62 can be placed on the adjustable cap after thecap has been manufactured.

FIG. 8 illustrates an adjustable cap 64 formed in the same manner as thecap shown in FIGS. 1-2 without a bill attached to the front 20. However,the adjustable cap 64 includes the movable ear flap 32 and the pair ofexpansion zones 50, 52 such that the adjustable cap 64 can be worn bywearers having different head sizes.

FIG. 9 illustrates an adjustable headband 66 constructed in accordancewith the present invention. The adjustable headband 66 includes anabbreviated crown portion 68 that includes the pair of expansion zones50, 52. Further, the adjustable headband 66 includes the movable earflap 32 that covers the expansion zones 50, 52 in the retracted positionshown.

FIG. 10 illustrates an adjustable visor 70 that includes the sameabbreviated crown portion 68 and expansion zones 50, 52 and movable earflap 32, as shown in FIG. 9. However, the visor 70 includes a bill 72attached near the front of the visor 70.

1. Adjustable headwear, comprising: a crown portion shaped to fit overat least a portion of the wearer's head, the crown portion having afront, a back and opposite sides, the crown portion having a lowerperipheral edge defining a head opening; at least one expansion zoneformed in the crown portion, wherein the expansion zone comprises astretchable material that stretches to adjust the size of the headopening to fit wearers of different head size; and a movable ear flappositioned along the crown portion, the movable ear flap extending alongat least the back and opposite sides of the crown portion, the ear flapsbeing movable between a retracted position and an extended position,wherein the ear flap covers the expansion zone in the retractedposition.
 2. The adjustable headwear of claim 1 further comprising apair of expansion zones each formed in one of the sides of the crownportion.
 3. The adjustable headwear of claim 2 wherein both of the pairof expansion zones are covered by the ear flap when the ear flap is inthe retracted position.
 4. The adjustable headwear of claim 3 furthercomprising a brim attached to the front of the crown portion.
 5. Theadjustable headwear of claim 2 wherein each of the expansion zonesextends into the crown portion from the lower peripheral edge.
 6. Theadjustable headwear of claim 5 wherein the crown portion is shaped tofit over the entire crown of a wearer's head, the crown portion beingformed from a plurality of gores sewn together.
 7. The adjustableheadwear of claim 6 wherein each of the expansion zones is formed in oneof the gores.
 8. The adjustable headwear of claim 2 further comprising aheadband attached to an interior surface of the crown portion along thelower peripheral edge, the headband configured to contact the wearer'shead, wherein the headband is removed in the pair of expansion zones. 9.An adjustable cap, comprising: a crown portion shaped to fit over thecrown of a wearer's head, the crown portion having an outer surface, afront, a back, opposite sides and a lower peripheral edge defining ahead opening; a pair of expansion zones formed in the opposite sides ofthe crown portion, wherein the expansion zones comprise a stretchablematerial that stretches to adjust the size of the head opening; and amovable ear flap positioned along the outer surface of the crown portionand extending along the back and the opposite sides of the crownportion, the ear flaps being movable between a retracted position and anextended position, wherein the ear flap covers the expansion zone in theretracted position.
 10. The adjustable cap of claim 9 wherein a bottomedge of the ear flap is generally aligned with the lower peripheral edgeof the crown portion when the ear flap is in the retracted position. 11.The adjustable cap of claim 9 wherein each of the expansion zonesextends into the crown portion from the lower peripheral edge.
 12. Theadjustable cap of claim 11 wherein the crown portion is formed from aplurality of gores sewn together.
 13. The adjustable cap of claim 12wherein each of the expansion zones is formed in one of the gores. 14.The adjustable cap of claim 9 further comprising a headband attached toan inner surface of the crown portion along the lower peripheral edge,the headband being configured to contact the wearer, wherein theheadband is removed in the pair of expansion zones.